Photonic device and method having increased quantum effect length

ABSTRACT

Photonic devices and methods having an increased quantum effect length are provided. In some embodiments, a photonic device includes a substrate having a first surface. A cavity extends into the substrate from the first surface to a second surface. A semiconductor layer is disposed on the second surface in the cavity of the substrate, and a cover layer is disposed on the semiconductor layer. The semiconductor layer is configured to receive incident radiation through the substrate and to totally internally reflect the radiation at an interface between the semiconductor layer and the cover layer.

BACKGROUND

Photonic devices, such as image sensors, photodetectors, photosensors,or the like, are sensors of light or other electromagnetic radiation.Such devices generally convert incident light photons into an electricalsignal, such as a current. The incident light may be converted tocurrent by a semiconductor material, which absorbs photons therebycausing electrons to transition from the conduction band of the materialto free electrons.

Photonic devices generally have a quantum efficiency that is limited bythe dimension of the semiconductor material (or quantum effect material)that absorbs the photons to generate the electrical signal. Quantumefficiency (QE) is the fraction of incident photons that contribute tothe electric signal

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

Aspects of the present disclosure are best understood from the followingdetailed description when read with the accompanying figures. It isnoted that, in accordance with the standard practice in the industry,various features are not drawn to scale. In fact, the dimensions of thevarious features may be arbitrarily increased or reduced for clarity ofdiscussion.

FIG. 1 is a cross-sectional view illustrating a device in accordancewith some embodiments of the present disclosure.

FIG. 2 illustrates total internal reflection of light at an interfacebetween a first material having a first refractive index η₁ and a secondmaterial having a second refractive index η₂.

FIGS. 3A through 3E are cross-sectional views illustrating a method offorming a photodetector device, such as the device shown in FIG. 1 , insome embodiments.

FIG. 4 is a cross-sectional view illustrating an imaging device inaccordance with some embodiments.

FIG. 5A is cross-sectional view illustrating a device, and FIG. 5B is aperspective view illustrating the semiconductor layer of the device ofFIG. 5A, in accordance with some embodiments.

FIG. 6A is cross-sectional view illustrating a device, and FIG. 6B is aperspective view illustrating the semiconductor layer of the device ofFIG. 6A, in accordance with some embodiments.

FIG. 7A is cross-sectional view illustrating a device, and FIG. 7B is aperspective view illustrating the semiconductor layer of the device ofFIG. 7A, in accordance with some embodiments.

FIG. 8A is cross-sectional view illustrating a device, and FIG. 8B is aperspective view illustrating the semiconductor layer of the device ofFIG. 8A, in accordance with some embodiments.

FIG. 9A is cross-sectional view illustrating a device, and FIG. 9B is aperspective view illustrating the semiconductor layer of the device ofFIG. 9A, in accordance with some embodiments.

FIG. 10A is cross-sectional view illustrating a device, and FIG. 10B isa perspective view illustrating the semiconductor layer of the device ofFIG. 10A, in accordance with some embodiments.

DETAILED DESCRIPTION

The following disclosure provides many different embodiments, orexamples, for implementing different features of the provided subjectmatter. Specific examples of components and arrangements are describedbelow to simplify the present disclosure. These are, of course, merelyexamples and are not intended to be limiting. For example, the formationof a first feature over or on a second feature in the description thatfollows may include embodiments in which the first and second featuresare formed in direct contact, and may also include embodiments in whichadditional features may be formed between the first and second features,such that the first and second features may not be in direct contact. Inaddition, the present disclosure may repeat reference numerals and/orletters in the various examples. This repetition is for the purpose ofsimplicity and clarity and does not in itself dictate a relationshipbetween the various embodiments and/or configurations discussed.

Further, spatially relative terms, such as “beneath,” “below,” “lower,”“above,” “upper” and the like, may be used herein for ease ofdescription to describe one element or feature's relationship to anotherelement(s) or feature(s) as illustrated in the figures. The spatiallyrelative terms are intended to encompass different orientations of thedevice in use or operation in addition to the orientation depicted inthe figures. The apparatus may be otherwise oriented (rotated 90 degreesor at other orientations) and the spatially relative descriptors usedherein may likewise be interpreted accordingly.

Reference throughout the specification to deposition techniques fordepositing dielectric layers, metals, or any other materials includessuch processes as chemical vapor deposition (CVD), low-pressure chemicalvapor deposition (LPCVD), metal organic chemical vapor deposition(MOCVD), plasma-enhanced chemical vapor deposition (PECVD), plasma vapordeposition (PVD), atomic layer deposition (ALD), molecular beam epitaxy(MBE), electroplating, electro-less plating, and the like. Specificembodiments are described herein with reference to examples of suchprocesses. However, the present disclosure and the reference to certaindeposition techniques should not be limited to those described.

Reference throughout the specification to etching techniques forselective removal of semiconductor materials, dielectric materials,metals, or any other materials includes such processes as dry etching,wet chemical etching, reactive ion (plasma) etching (ME), washing, wetcleaning, pre-cleaning, spray cleaning, chemical-mechanicalplanarization (CMP) and the like. Specific embodiments are describedherein with reference to examples of such processes. However, thepresent disclosure and the reference to certain etching techniquesshould not be limited to those described.

Some image sensors, such as complementary metal-oxide-semiconductor(CMOS) image sensors, include a semiconductor substrate (e.g., ofmonocrystalline silicon) and an array of photodetectors arranged in thesemiconductor substrate. The photodetectors are formed in thesemiconductor substrate and circuitry such as transistors is arranged onor in the semiconductor substrate and electrically coupled to thephotodetectors. The photodetectors are configured to absorb incidentradiation and to generate an electric signal corresponding to theincident radiation.

A challenge with image sensors is that incident radiation has a pathlength (which may be referred to herein as a “quantum effect length”)that is limited by a dimension of the photodetectors. Therefore, thephotodetectors generally have a quantum efficiency that is similarlylimited by the dimension of the photodetectors. Quantum efficiency (QE)is the fraction of incident photons which contribute to the electricsignal.

One potential approach for enhancing the quantum efficiency of CMOSimage sensors is to increase the thickness of the semiconductorsubstrate and increase the depth to which the photodetectors extend intothe semiconductor substrate. By increasing the depth of thephotodetectors, the quantum effect length of incident radiationtraveling through the photodetectors may be increased, therebyincreasing the quantum efficiency of the image sensor. However, this isdifficult with existing CMOS processes and adds cost to the manufactureof the CMOS image sensors. Further, increasing the depth to which thephotodetectors extend into the semiconductor substrate increases crosstalk and die size.

In view of the foregoing, various embodiments of the present applicationare directed towards photonic devices, structures, and methods in whicha semiconductor layer that receives incident irradiation and convertsthe received irradiation into an electrical signal has a high quantumefficiency. The quantum efficiency may be achieved by increasing thequantum effect length of the received irradiation through thesemiconductor material, which in some embodiments is facilitated bytotal internal reflection of the irradiation within the semiconductormaterial.

FIG. 1 is a cross-sectional view illustrating a device 10 in accordancewith one or more embodiments of the present disclosure.

The device 10 may be, in various embodiments, any structure suitable toconvert an optical signal into an electrical signal. In someembodiments, the device 10 is a photodetector which may be included inan image sensor, such as a CMOS image sensor.

As shown in FIG. 1 , the device 10 includes a substrate 12. A cavity 14extends into the substrate 12, for example, from a front surface 16 ofthe substrate 12 toward a back surface 17 of the substrate 12 that isopposite the front surface 16. In alternative embodiments, the cavity 14may extend into the substrate 12 from the back surface 17 toward thefront surface 16. The cavity 14 is shown having a rectangular view incross-section; however, embodiments of the present disclosure are notlimited thereto. In various embodiments, the cavity 14 may have anyshape. In various embodiments, the cavity 14 may have a generallyrectangular or cubic shape, a circular, rounded, or cylindrical shape,or any other suitable shape.

In some embodiments, the cavity 14 has a width (e.g., along the X-axisdirection as shown in FIG. 1 ) that is less than 750 μm. In someembodiments, the cavity 14 has a length (e.g., along the Z-axisdirection) that is less than 750 μm. In some embodiments, the cavity 14has a height or depth (e.g., along the Y-axis direction) that is lessthan 700 μm. However, embodiments of the present embodiment are notlimited thereto, and in various embodiments, the cavity 14 may havevarious different dimensions and shapes.

The substrate 12 may be any suitable semiconductor substrate. In variousembodiments, the substrate 12 may be formed of a crystallinesemiconductor material, for example, monocrystalline silicon,polycrystalline silicon, or some other type of crystalline semiconductormaterial. In some embodiments, the substrate 12 is a silicon substrate;however, embodiments provided herein are not limited thereto. Forexample, in various embodiments, the substrate 12 may include galliumarsenide (GaAs), gallium nitride (GaN), silicon carbide (SiC), or anyother semiconductor material. The substrate 12 may include variousdoping configurations depending on design specifications. In someembodiments, the substrate 12 is a p-type substrate having aconcentration of p-type dopants. In other embodiments, the substrate 12is a n-type substrate having a concentration of n-type dopants.

A semiconductor layer 18 is formed in the cavity 14 of the substrate 12.The semiconductor layer 18 may be formed of any semiconductor materialsuitable to absorb radiation (e.g., from incident light) and to generatean electrical signal based on the absorbed radiation. In someembodiments, the semiconductor layer 18 is formed of a semiconductormaterial that is different from a semiconductor material of thesubstrate 12. In some embodiments, the semiconductor layer 18 is anepitaxial semiconductor layer.

In various embodiments, the semiconductor layer 18 may be formed of, forexample, germanium (Ge), silicon germanium (SiGe), any Group III-Vsemiconductor material or Group III-V compound semiconductor materials,or any other semiconductor material suitable to absorb radiation andgenerate an electrical signal based on the absorbed radiation. In someembodiments, the semiconductor layer 18 be formed of a semiconductormaterial that has a low energy bandgap, and the low energy bandgap maybe, for example, an energy bandgap that is less than about 1 electronvolt (eV). In some embodiments, the semiconductor layer 18 may have anenergy bandgap that is less than an energy bandgap of the substrate 12.

The electric signal generated by the semiconductor layer 18 may, forexample, result from electron-hole pairs generated in response toabsorbing photons of the radiation 30.

As shown in FIG. 1 , the semiconductor layer 18 includes side surfaces19, an upper surface 21, and one or more facets or angled surfaces 23which extend between the side surfaces 19 and the upper surface 21. Theside surfaces 19 of the semiconductor layer 18 may be spaced apart fromcorresponding sidewalls of the substrate 12 within the cavity 14.

In some embodiments, the semiconductor layer 18 has a height (e.g.,along the Y-axis direction, as shown in FIG. 1 ) that is greater thanthe depth of the cavity 14. For example, as shown in FIG. 1 , at least aportion of the semiconductor layer 18 may extend in the Y-axis directionbeyond the front surface 16 of the substrate 12. In some embodiments,the height of the semiconductor layer 18 may be less than 750 μm. Insome embodiments, the height of the semiconductor layer 18 may be lessthan 500 μm, less than 300 μm, or less than 200 μm. As will be describedin greater detail later herein, the height of the semiconductor layer 18may be reduced by several orders while providing a good quantum effectlength, due to total internal reflection of radiation within thesemiconductor layer 18. That is, due to total internal reflection ofradiation within the semiconductor layer 18, the height, as well asother dimensions of the semiconductor layer 18, may be significantlyreduced as compared to structures in which radiation is not totallyinternally reflected. The semiconductor layer 18 may have a width (e.g.,along the X-axis direction) that is less than the width of the cavity14.

The device 10 further includes a cover layer 20 on the semiconductorlayer 18 and the substrate 12. The cover layer 20 covers thesemiconductor layer 18. For example, as shown in FIG. 1 , the coverlayer 20 covers the upper surface 21, the angled surfaces 23, and theside surfaces 19 of the semiconductor layer 18. In some embodiments, thecover layer 20 directly contacts the upper surface 21, the angledsurfaces 23, and the side surfaces 19 of the semiconductor layer 18. Insome embodiments, the cover layer 20 completely surrounds thesemiconductor layer 18, except for a surface of the semiconductor layer18 that contacts the substrate 12 (e.g., except for the lower surface ofthe semiconductor layer 18 as shown in FIG. 1 ).

The device 10 may further include sidewall spacers 22 that extendbetween sidewalls of the substrate 12 and facing side surfaces 19 of thesemiconductor layer 18. The sidewall spacers 22 may be formed of anydielectric material, and in some embodiments, the sidewall spacers 22are formed of a same material as the cover layer 20. In someembodiments, the sidewall spacers 22 may be portions of the cover layer20. That is, portions of the cover layer 20 may extend into the spacesbetween the sidewalls of the substrate 19 and the side surfaces 19 ofthe semiconductor layer 18.

In some embodiments, the sidewall spacers 22 have a width (between thesidewalls of the substrate 12 and the facing side surfaces 19 of thesemiconductor layer 18) suitable to prevent or impede growth of thesemiconductor layer 18 on or from the sidewalls of the substrate 12, forexample, during formation of the semiconductor layer 18. In someembodiments, the width of the sidewall spacers 22 is less than 50 μm. Insome embodiments, the width of the sidewall spacers 22 is less than 10μm. In some embodiments, the width of the sidewall spacers 22 is withina range from 50 nm to 10 μm, inclusive.

In some embodiments, the cover layer 20 may be a cover film and may beformed of any electrically insulating or dielectric material. In someembodiments, the cover layer 20 is formed of or includes silicon oxide(SiO_(x)), silicon oxynitride (SiON), silicon nitride (SiN), or thelike. Similarly, the sidewall spacers 22 may be formed of anyelectrically insulating or dielectric material, including one or more ofsilicon oxide (SiO_(x)), silicon oxynitride (SiON), silicon nitride(SiN), or the like.

The device 10 may further include a dielectric layer 24 between thecover layer 20 and the front surface 16 of the substrate 12. Thedielectric layer 24 may be formed of or include any dielectric material.In some embodiments, the dielectric layer 24 is formed of or includesoxide, nitride, silicon oxide (SiO_(x)), silicon oxynitride (SiON),silicon nitride (SiN), or the like. In some embodiments, the dielectriclayer 24 extends directly between the front surface 16 of the substrate12 and the cover layer 20. The dielectric layer 24 may have edges thatare aligned with the side surfaces of the cavity 14 in the substrate 12,as shown in FIG. 1 .

In some embodiments, the semiconductor layer 18 has a refractive indexη₁ that is greater than a refractive index η₂ of the cover layer 20.This facilitates total internal reflection of radiation 30 (e.g., light)within the semiconductor layer 18. As shown in FIG. 1 , radiation 30 maybe received at the back surface 17 of the substrate 12 and may betransmitted through the substrate 12 into the semiconductor layer 18.The radiation 30 is totally internally reflected within thesemiconductor layer 18. For example, the radiation 30 may be totallyinternally reflected at the interface of the angled surfaces 23 of thesemiconductor layer 18 and the cover layer 20. In some embodiments, therefractive index η₁ of the semiconductor layer 18 is within a range from1 to 10, and the refractive index 112 of the cover layer 20 is within arange from 0 to 9, and the refractive index η₂ of the cover layer 20 isless than the refractive index η₁ of the semiconductor layer 18. In someembodiments, the refractive index η₁ of the semiconductor layer 18 iswithin a range from 2 to 6, and the refractive index 112 of the coverlayer 20 is within a range from 0 to 2.

Total internal reflection is described in further detail below withreference to FIG. 2 . FIG. 2 illustrates total internal reflection oflight at an interface 101 between a first material 102 having a firstrefractive index η₁ and a second material 104 having a second refractiveindex η₂. The first material 102 may represent the semiconductor layer18 of the device 10, and the second material 104 may represent the coverlayer 20.

Total internal reflection occurs when the angle of incidence of thelight is greater than the critical angle θ_(C). The critical angle θ_(C)is the smallest angle of incidence that yields total reflection. For aninterface between two materials having different refractive indices(e.g., the interface 101 between the first and second materials 102,104), the critical angle θ_(C) is given by the following equation:θ_(c)=arcsin(n ₂ /n ₁).

In embodiments in which the semiconductor layer 18 is germanium and thecover layer 20 is silicon oxide, the semiconductor layer 18 may have afirst refractive index η₁ of about 4 and the cover layer 20 may have asecond refractive index η₂ of about 1.46. Accordingly, the criticalangle θ_(C) is 21.4°. The critical angle θ_(C) and the angles ofincidence of light are measured with respect to the normal 103 to theinterface 101 between the first and second materials 102, 104.

In the example shown in FIG. 2 , a first light 106 having an angle ofincidence θ₁ that is less than the critical angle θ_(C) is onlypartially reflected at the interface 101 between the first material 102and the second material 104. That is, a first portion 1061 of the firstlight 106 is refracted and transmitted into the second material 104,while a second portion 1062 of the first light 106 is reflected at theinterface 101. In contrast, a second light 108 having an angle ofincidence θ₂ that is greater than the critical angle θ_(C) is totallyinternally reflected at the interface 101 between the first material 102and the second material 104.

Referring again to FIG. 1 , the radiation 30 may be totally internallyreflected at the interface of the angled surfaces 23 of thesemiconductor layer 18 and the cover layer 20. The presence of theangled surfaces 23 facilitates total internal reflection of theradiation 30. For example, without the angled surfaces 23, light that istransmitted along the direction of the radiation 30 would encounter asurface (e.g., upper surface of the semiconductor layer 18) that issubstantially orthogonal to the direction of the light, and the angle ofincidence with respect to the normal to such a surface would besubstantially 0°, which is less than the critical angle. In such a case,the light would not be totally internally reflected and some, if notmost or even all, of the light would be transmitted into the cover layer20.

On the other hand, as shown in FIG. 1 , due at least in part to thepresence of the angled surfaces 23 of the semiconductor layer 18, theangle of incidence of the radiation 30 at the interface between theangled surfaces 23 and the cover layer 20 may be greater than thecritical angle, and thus the radiation 30 may be totally internallyreflected within the semiconductor layer 18. Moreover, as shown in FIG.1 , the radiation may be totally internally reflected at a first angledsurface 23 (e.g., shown on the right-hand side) and may again be totallyinternally reflected at a second angled surface 23 (e.g., shown on theleft-hand side), and the radiation 30 may then be transmitted throughthe semiconductor layer 18 toward and through the front surface 16 ofthe substrate 12.

The angled surfaces 23 have an inclination angle θ (e.g., with respectto the lower surface 15 of the substrate 12 in the cavity 14, or withrespect to a horizontal line as shown), which may be any angle suitableto facilitate total internal reflection of radiation at the interface ofthe angled surfaces 23 and the cover layer 20. In some embodiments, theinclination angle θ is between 0° and 90°. In some embodiments, theinclination angle θ is between 30° and 60°, and in some embodiments, theinclination angle θ is between 40° and 50°.

Due to the total internal reflection of the radiation 30, a path length(or quantum effect length) of the radiation 30 within the semiconductormaterial 18 may be extended, which increases quantum efficiency (QE) ofthe of the semiconductor material 18, as the quantum effect length isincreased, thereby increasing an amount or fraction of the photonswithin the radiation 30 that contribute to the electric signal generatedby the semiconductor material 18. Since the distance that light travelsthrough the semiconductor material 18 (e.g., the quantum effect length)is increased due to the total internal reflection of the light, andsince the quantum efficiency is similarly increased, the size ordimensions of the semiconductor material 18 may be reduced as comparedto a size or dimensions of semiconductor material in which radiation isnot internally reflected, while providing a same quantum effect lengththrough the semiconductor material 18.

The semiconductor material 18 may have various different shapes anddimensions, which may be selected to provide a desired quantum effectlength. The shape and dimensions for the semiconductor material 18 shownin FIG. 1 are provided merely as an example, and various other shapesand dimensions may be utilized in various embodiments, for example, aswill be described later herein with respect to FIGS. 5A to 10B.Additionally, it is noted that in various embodiments, total internalreflection of incident radiation at the interface of the semiconductormaterial 18 and the cover layer 20 may be achieved, at least in part, inconjunction with one or more lenses or microlenses configured to director focus the incident radiation so that the incidence angle of theradiation at one or more interfaces between the semiconductor material18 and the cover layer 20 will be greater than the critical angle θ_(C).

In some embodiments, the device 10 may be configured to receive incidentradiation 30 and to totally internally reflect the radiation 30 at leastone time within the semiconductor material 18. In some embodiments, thedevice 10 may be configured to totally internally reflect the radiation30 at least two times within the semiconductor material 18, for example,as shown in FIG. 1 .

FIGS. 3A through 3E are cross-sectional views illustrating a method offorming a photodetector device, such as the device 10 shown in FIG. 1 ,in some embodiments.

As shown in FIG. 3A, a dielectric layer 24 is formed on a substrate 12.In some embodiments, the substrate 12 is a silicon substrate; however,embodiments provided herein are not limited thereto. For example, invarious embodiments, the substrate 12 may include gallium arsenide(GaAs), gallium nitride (GaN), silicon carbide (SiC), or any othersemiconductor material. In some embodiments, the substrate 12 is ap-type substrate having a concentration of p-type dopants, and in otherembodiments the substrate 12 is a n-type substrate having aconcentration of n-type dopants.

In some embodiments, the dielectric layer 24 is formed of or includesoxide, nitride, silicon oxide (SiO_(x)), silicon oxynitride (SiON),silicon nitride (SiN), or the like. The dielectric layer 24 may beformed by any suitable process, including, for example, deposition,anodization, thermal oxidation, or the like. In some embodiments, thedielectric layer 24 is formed by a deposition process. The depositionprocess may be any suitable deposition process for depositing adielectric layer, including, for example, chemical vapor deposition(CVD), low-pressure chemical vapor deposition (LPCVD), plasma-enhancedchemical vapor deposition (PECVD), plasma vapor deposition (PVD), atomiclayer deposition (ALD), or the like. In some embodiments, the dielectriclayer 24 has a thickness of less than 200 μm. In some embodiments, thedielectric layer 24 has a thickness of less than 100 μm, and in someembodiments, the dielectric layer 24 has a thickness of less than 50 μm.

As shown in FIG. 3B, a cavity 14 is formed by removing portions of thedielectric layer 24 and the substrate 12. The portions of the dielectriclayer 24 and the substrate 12 may be removed by any suitable process,including, for example, by an etching process. In some embodiments, amask is formed over regions of the dielectric layer 24 and exposesportions of the dielectric layer 24 that will be removed. An etchant maythen be utilized to remove the exposed portions of the dielectric layer24, as well as portions of the substrate 12 underlying the dielectriclayer 24. Any suitable etchant may be utilized, including, for example,any suitable dry etchant or wet etchant such as hydrofluoric acid. Themask may then be removed, leaving the dielectric layer 24 on the frontsurface 16 of the substrate 12.

The cavity 14 may have any suitable shape. In various embodiments, thecavity 14 may have a generally rectangular or cubic shape, a circular,rounded, or cylindrical shape. In some embodiments, one or more angledsurfaces may be formed in the cavity 14, for example, between sidewallsand a lower surface of the cavity. In some embodiments, the cavity 14has a width that is less than 750 μm. In some embodiments, the cavity 14has a length that is less than 750 μm. In some embodiments, the cavity14 has a height or depth that is less than 700 μm. However, embodimentsof the present embodiment are not limited thereto, and in variousembodiments, the cavity 14 may have various different dimensions andshapes.

As shown in FIG. 3C, sidewall spacers 22 are formed on sidewalls of thesubstrate 12 in the cavity 14. The sidewall spacers 22 may be formed byany suitable process, including, for example, deposition, anodization,thermal oxidation, or the like. In some embodiments, the sidewallspacers 22 may be formed by thermal oxidation to produce a thin layer ofoxide (e.g., silicon dioxide) on the exposed surfaces of the substrate12 within the cavity 14. In a thermal oxidation process, an oxidizingagent is forced to diffuse into the substrate 12 at a suitably hightemperature and the oxidizing agent reacts with the substrate to formthe oxide layer. In some embodiments, portions of the oxide on surfacesof the substrate 12 other than the sidewalls (e.g., portions on a floorof the cavity 14 or on an upper surface of the substrate 12) areremoved, leaving only the oxide on the sidewalls of the substrate 12,which form the sidewall spacers 12. The portions of the oxide may beremoved by any suitable process, including, for example, by ananisotropic etching process.

In some embodiments, the sidewall spacers 22 have a width suitable toprevent or impede growth of the subsequently formed semiconductor layer18 on or from the sidewalls of the substrate 12, for example, duringformation of the semiconductor layer 18. In some embodiments, the widthof the sidewall spacers 22 is less than 50 μm. In some embodiments, thewidth of the sidewall spacers 22 is less than 10 μm. In someembodiments, the width of the sidewall spacers 22 is within a range from50 nm to 10 μm, inclusive.

In some embodiments, the sidewall spacers 22 extend from a floor orlower surface 15 of the substrate 12 within the cavity 14 to a levelthat is substantially coplanar with an upper surface of the substrate12. However, embodiments of the present disclosure are not limitedthereto, and in various embodiments, the sidewall spacers 22 may haveupper surfaces that are above or below a level of the upper surface ofthe substrate 12.

As shown in FIG. 3D, a semiconductor layer 18 is formed in the cavity 14of the substrate 12. The semiconductor layer 18 may be formed of anysemiconductor material suitable to absorb radiation (e.g., from incidentlight) and to generate an electrical signal based on the absorbedradiation. In some embodiments, the semiconductor layer 18 is formed ofa semiconductor material that is different from a semiconductor materialof the substrate 12. In some embodiments, the semiconductor layer 18 isan epitaxial semiconductor layer formed of germanium (Ge), silicongermanium (SiGe), any Group III-V semiconductor material or Group III-Vcompound semiconductor materials, or any other semiconductor materialsuitable to absorb radiation and generate an electrical signal based onthe absorbed radiation.

The semiconductor layer 18 may be epitaxially grown from the exposedsurface of the substrate 12 in the cavity 14 (e.g., the lower surface orfloor of the cavity 14). The sidewall spacers 22 prevent or impedegrowth of the semiconductor layer 18 from the sidewalls of the substrate12, so the semiconductor layer 18 grows upward from the floor of thesubstrate 12 in the cavity 14 and is spaced apart from the sidewalls ofthe substrate 12 by the sidewall spacers 22. The growth of thesemiconductor layer 18 may be constrained laterally by the sidewallspacers 22. At the upper surface of the sidewall spacers 22, thesemiconductor layer 18 forms one or more facets or angled surfaces 23which extend between the side surfaces 19 and the upper surface 21 ofthe semiconductor layer 18. The semiconductor layer 18 may be formed ofa crystalline structure that naturally grows in faceted shapes, therebyforming the angled surfaces 23 once the semiconductor layer 18 is grownoutwardly beyond the upper surface of the sidewall spacers 22.

The shapes (e.g., the angled surfaces 23) of the semiconductor layer 18are a consequence of the crystal structure of the material of thesemiconductor layer 18 and the surface energy, as well as the generalconditions under which the crystal formed. The shapes of thesemiconductor layer 18 may be variously formed depending on variousfactors, such as selected or desired growth conditions (e.g.,temperature, humidity, pressure, etc.), the crystal orientation of thesurface the semiconductor layer 18 is grown on (e.g., of the exposedsurface of the substrate 12 in the cavity 14), stress from the substrate12, the relative energies of the different planes, and the like.

In some embodiments, the semiconductor layer 18 is formed to have aheight that is greater than the depth of the cavity 14, and a portion ofthe semiconductor layer 18 may extend outwardly (e.g., in the Y-axisdirection) beyond the front surface 16 of the substrate 12. In someembodiments, the height of the semiconductor layer 18 may be less than750 μm. In some embodiments, the height of the semiconductor layer 18may be less than 500 μm, less than 300 μm, or less than 200 μm.

As shown in FIG. 3E, a cover layer 20 is formed on the semiconductorlayer 18. The cover layer 20 may be formed by any suitable process,including, for example, deposition, anodization, thermal oxidation, orthe like. In some embodiments, the cover layer 20 is formed by adeposition process. The deposition process may be any suitabledeposition process for depositing a dielectric layer, including, forexample, chemical vapor deposition (CVD), low-pressure chemical vapordeposition (LPCVD), plasma-enhanced chemical vapor deposition (PECVD),plasma vapor deposition (PVD), atomic layer deposition (ALD), or thelike.

The cover layer 20 may be formed to cover the semiconductor layer 18,for example, the cover layer 20 may be formed to cover the upper surface21, the angled surfaces 23, and the side surfaces 19 of thesemiconductor layer 18. In some embodiments, the cover layer 20 directlycontacts the upper surface 21, the angled surfaces 23, and the sidesurfaces 19 of the semiconductor layer 18. In some embodiments, thecover layer 20 completely surrounds the semiconductor layer 18, exceptfor a surface of the semiconductor layer 18 that contacts the substrate12 (e.g., except for the lower surface of the semiconductor layer 18).

In some embodiments, the cover layer 20 may be a cover film and may beformed of any electrically insulating or dielectric material. In someembodiments, the cover layer 20 is formed of or includes silicon oxide(SiO_(x)), silicon oxynitride (SiON), silicon nitride (SiN), or thelike. In some embodiments, the cover layer 20 may be formed of a samematerial as the sidewall spacers 22.

Although FIGS. 3A through 3E illustrate a method of forming aphotodetector device, such as the device 10 shown in FIG. 1 , it will bereadily appreciated that in various embodiments, the method illustratedin FIGS. 3A to 3E may be implemented to form a plurality ofphotodetector devices, such as an array of photodetectors or pixels. Forexample, a plurality of photodetectors may be manufactured adjacent toone another, e.g., in an array, by the illustrated method.

FIG. 4 is a cross-sectional view illustrating an imaging device 100 inaccordance with one or more embodiments of the present disclosure. Theimaging device 100 may be any device that converts received irradiationinto an electrical signal, and in some embodiments, the imaging device100 may be an image sensor such as a CMOS image sensor.

The imaging device 100 includes a photonic wafer 102 and a CMOS wafer202. The photonic wafer 102 includes a plurality of photodetectors 110formed in a substrate 112. The substrate 112 may be substantially thesame or identical to the substrate 12, and the photodetectors 110 may besubstantially the same or identical to the device 10 shown and describedwith respect to FIGS. 1 through 3E. For example, each of thephotodetectors 110 may include a respective semiconductor layer formedin a cavity in the substrate 112, and the semiconductor layer mayinclude one or more facets or angled surfaces which may operablyincrease a quantum path length of received light 111. Further, while notexplicitly shown in FIG. 4 , the photodetectors 110 may include a coverlayer, such as the cover layer 20, which covers the semiconductor layer,and the semiconductor layer may have a refractive index that is greaterthan a refractive index of the cover layer.

The photodetectors 110 of the photonic wafer 102 may be formed as apixel array of photodetectors. For example, the photodetectors 110 maybe arranged as an array having rows and columns of the photodetectors110. The imaging device 100 may be a backside illumination device, withirradiation being received at a backside of the photonic wafer 102, asshown.

In some embodiments, a dielectric layer 134 is formed on a backside ofthe substrate 112 of the photonic wafer 102. Optical lenses 136 may beformed on the dielectric layer 134, and the optical lenses 136 areconfigured to focus the received light 111 to a respective photodetector110. In some embodiments, the optical lenses 136 are microlenses, witheach of the microlenses having a width that is similar to (and in someembodiments, slightly greater than) the width of the photodetectors 110.

An interconnect structure 138 is formed on a back side of thephotodetectors 110 and forms a backside of the photonic wafer 102. Theinterconnect structure 138 includes an interlayer dielectric (ILD) layer140, and a plurality of metal layers 142, which may form various wiringlayers, vias, or any conductive pathways for transmitting electricalcharges received from the photodetectors 110. The ILD layer 140 may be,for example, silicon dioxide, silicon nitride, a low κ dielectric (e.g.,fluorosilicate glass (FSG)), some other dielectric, or a combination ofthe foregoing. A low κ dielectric is a dielectric with a dielectricconstant κ less than about 3.9, 3.0, 2.0, or 1.0.

The metal layers 142 are variously arranged within the ILD layer 140,for example, with metal lines and vias electrically coupling the metallines together. The metal layers 142 may be formed of a conductivematerial, such as, for example, aluminum copper, copper, aluminum,tungsten, some other conductive material, or a combination of theforegoing. The metal layers 142 electrically couple the photodetectors110 to bonding pads 144 at a front side of the photonic wafer 102.Accordingly, the metal layers 142 may transmit electrical signalsreceived from the photodetectors 110 to the bonding pads 144. Thebonding pads 144 may be formed of any conductive material, and in someembodiments, the bonding pads 144 are formed of aluminum copper,aluminum germanium, copper tin, some other conductive material, or acombination of the foregoing.

The CMOS wafer 202 includes a substrate 212 and electrical circuitry 250formed in or on the substrate 212. The substrate 212 may be any suitablesemiconductor substrate. In various embodiments, the substrate 212 maybe formed of a crystalline semiconductor material, for example,monocrystalline silicon, polycrystalline silicon, or some other type ofcrystalline semiconductor material. In some embodiments, the substrate212 is a silicon substrate; however, embodiments provided herein are notlimited thereto. For example, in various embodiments, the substrate 212may include gallium arsenide (GaAs), gallium nitride (GaN), siliconcarbide (SiC), or any other semiconductor material. In some embodiments,the substrate 212 may be substantially the same as the substrate 112 ofthe photonic wafer 102.

The electrical circuitry 250 is configured to receive and process theelectrical signals generated by the photodetectors 110 in response toreceiving the light 111. The electrical circuitry 240 may include, forexample, logic or memory devices configured to read or store datagenerated by the photodetectors 110 in response to incident light 111.In some embodiments, the electrical circuitry 240 may include pixeltransistors corresponding to the photodetectors 110 to facilitatereadout of the photodetectors 110.

The CMOS wafer 202 includes an interconnect structure 238 on thesubstrate 212. The interconnect structure 238 may be substantiallysimilar to the interconnect structure 138 of the photonic wafer 102. Forexample, the interconnect structure may include an ILD layer 240, and aplurality of metal layers 242, which may form various wiring layers,vias, or any conductive pathways for transmitting the electrical chargesreceived from the photodetectors 110 to the electrical circuitry 250.The ILD layer 240 may be, for example, silicon dioxide, silicon nitride,a low κ dielectric (e.g., fluorosilicate glass (FSG)), some otherdielectric, or a combination of the foregoing.

The metal layers 242 are variously arranged within the ILD layer 240,for example, with metal lines and vias electrically coupling the metallines together. The metal layers 242 may be formed of a conductivematerial, such as, for example, aluminum copper, copper, aluminum,tungsten, some other conductive material, or a combination of theforegoing. The metal layers 242 electrically couple bonding pads 244 ata back side of the CMOS wafer 202 to the electrical circuitry 250.

The photonic wafer 102 is physically bonded to the CMOS wafer 202 by anysuitable bonding technique, including by the use of one or more bondingmaterials, adhesives, or the like. Once bonded together, the bondingpads 144 of the photonic wafer 102 are aligned with and electricallycoupled to corresponding bonding pads 244 of the CMOS wafer 202.Accordingly, the metal layers 242 of the CMOS wafer 202 operablytransmit electrical signals from the bonding pads 244 (which arereceived by the bonding pads 244 from the photodetectors 110) to theelectrical circuitry 250. The bonding pads 244 may be formed of anyconductive material, and in some embodiments, the bonding pads 244 areformed of aluminum copper, aluminum germanium, copper tin, some otherconductive material, or a combination of the foregoing.

FIG. 5A is cross-sectional view illustrating the device 10 and FIG. 5Bis a perspective view illustrating the semiconductor layer of the device10, in accordance with one or more embodiments of the presentdisclosure. The device 10 shown in FIGS. 5A and 5B is the same device 10shown and described previously herein with respect to FIG. 1 . Thefeatures of the device 10 previously described will not be describedherein with respect to FIGS. 5A and 5B in the interest of brevity.

As shown in FIG. 5A, an optical a path length (or quantum effect length)of the incident radiation 30 within the semiconductor layer 18 includesa first segment 31, a second segment 32, and a third segment 33. Theincident radiation 30 travels along the first segment 31 of the quantumeffect length until it encounters a first angled surface 23 (e.g., asshown on the right-hand side in FIG. 5A), where the radiation 30 istotally internally reflected at the interface between the first angledsurface 23 and the cover layer 20. The totally internally reflectedradiation then travels along the second segment 32 of the quantum effectlength until it encounters a second angled surface 23 (e.g., as shown onthe left-hand side in FIG. 5A), where it may again be totally internallyreflected, at which point the radiation 30 travels along the thirdsegment 33 of the quantum effect length and may exit through thesubstrate 12. The total internal reflection of the radiation 30 withinthe semiconductor layer 18 thus extends the quantum effect length ascompared to structures in which radiation is not totally internallyreflected. As shown in FIG. 5A, the incident radiation 30 may be totallyinternally reflected at two interfaces within the semiconductor layer18, e.g., at interfaces between each of the angled surfaces 23 and thecover layer 20.

FIG. 6A is cross-sectional view illustrating a device 310 and FIG. 6B isa perspective view illustrating the semiconductor layer of the device310, in accordance with one or more embodiments of the presentdisclosure. The device 310 shown in FIGS. 6A and 6B is substantiallysimilar in many respects to the device 10 shown and described previouslyherein with respect to FIG. 1 . The description of the device 310 willfocus on the differences from the device 10 previously described herein.As shown in FIGS. 6A and 6B, the semiconductor layer 18 of the device310 includes angled surfaces 325 at a lower side of the semiconductorlayer 18, in addition to the angled surfaces 323 at the upper side ofthe semiconductor layer 18 that extend between the side surfaces 319 andthe upper surface 321.

The angled surfaces 323 and upper surface 321 are substantially the sameor identical to the angled surfaces 23 and upper surface 21,respectively, of the device 10 shown and described previously herein.

The angled surfaces 325 of the device 310 extend between the lowersurface 315 and the side surfaces 319 of the semiconductor layer 18. Theangled surfaces 323 may be substantially symmetrical (e.g., along thehorizontal axis) to the angled surfaces 325. In some embodiments, theangled surfaces 325 have an inclination angle θ, which may be any anglesuitable to facilitate total internal reflection of radiation at theinterface of the angled surfaces 323 and the cover layer 20. In someembodiments, the inclination angle θ of the angled surfaces 325 issubstantially the same as the inclination angle of the angled surfaces323. In some embodiments, the inclination angle θ is between 0° and 90°.In some embodiments, the inclination angle θ is between 30° and 60°, andin some embodiments, the inclination angle θ is between 40° and 50°.

In some embodiments, the cavity 314 in the substrate 12 in which thesemiconductor layer 18 is formed may have a shape that substantiallycorresponds to a shape of a lower portion of the semiconductor layer 18.For example, the substrate 12 may have may have angled surfaces 345 inthe cavity 314 that substantially correspond to the angled surfaces 325of the semiconductor layer 18.

The device 310 may further include sidewall spacers 322 that extendbetween sidewalls of the substrate 12 and the semiconductor layer 18within the cavity 314, and the sidewall spacers 322 may be substantiallythe same as the sidewall spacers 22 previously described herein withrespect to the device 10, and may be formed of any dielectric material.The sidewall spacers 322 extend from the sidewalls and the angledsurfaces 345 of the substrate 12 in the cavity 340 to correspondingfacing surfaces of the semiconductor layer 18.

In some embodiments, the device 310 may include an opening 340 thatextends from the back surface 17 of the substrate 12 into the cavity 314in which the semiconductor layer 18 is formed. The opening 340 allowsincident radiation 30 to pass directly through the opening 340 so thatat least some of the radiation 30 does not pass through the substrate12. The opening 340 may be optional, and in some embodiments, theopening 340 may be omitted.

As shown in FIG. 6A, an optical a path length (or quantum effect length)of the incident radiation 30 within the semiconductor layer 18 includesa first segment 331, a second segment 332, a third segment 333, and afourth segment 334. The incident radiation 30 may be received at a firstlower angled surface 325 of the semiconductor layer 18 (e.g., as shownon the right-hand side in FIG. 6A) and travels along the first segment331 of the quantum effect length until it encounters a first upperangled surface 323 (e.g., as shown on the right-hand side in FIG. 6A),where the radiation 30 is totally internally reflected at the interfacebetween the first upper angled surface 323 and the cover layer 20. Thetotally internally reflected radiation then travels along the secondsegment 332 of the quantum effect length until it encounters a secondupper angled surface 323 (e.g., as shown on the left-hand side in FIG.6A), where it may again be totally internally reflected. The radiation30 then travels along the third segment 333 of the quantum effect lengthuntil it encounters a second lower angled surface 325 of thesemiconductor layer 18 (e.g., as shown on the left-hand side in FIG.6A), where the radiation 30 is totally internally reflected at theinterface between the second lower angled surface 325 and the coverlayer 20 or sidewall spacer 322 within the cavity 314. The radiation 30then travels along the fourth segment 334 of the quantum effect lengthuntil it again encounters the interface between the first lower angledsurface 325 of the semiconductor layer 18 and the cover layer 20 orsidewall spacer 322.

It will be readily appreciated that the device 310 shown in FIGS. 6A and6B may be formed by the method illustrated in FIGS. 3A through 3E withone or more modifications. For example, the cavity 314 may be formed bya substantially same process as described and illustrated with respectto FIG. 3B; however, the cavity 314 may be formed to have the angledsurfaces 345. Moreover, in some embodiments, portions of the substrate12 may be removed (e.g., by etching, or any suitable technique) to formthe opening 340. The sidewall spacers 322 may be formed by thermaloxidation, as described with respect to FIG. 3C; however, the sidewallspacers 322 of the device 310 may be formed on the sidewalls as well asthe angled surfaces 345 in the cavity 314. The semiconductor layer 18may be epitaxially grown from the exposed lower surface 315 of thesubstrate 12, as described with respect to FIG. 3D.

FIG. 7A is cross-sectional view illustrating a device 410 and FIG. 7B isa perspective view illustrating the semiconductor layer of the device410, in accordance with one or more embodiments of the presentdisclosure. The device 410 shown in FIGS. 7A and 7B is substantiallysimilar in many respects to the device 10 shown and described previouslyherein with respect to FIG. 1 . The description of the device 410 willfocus on the differences from the device 10 previously described herein.As shown in FIGS. 7A and 7B, the semiconductor layer 18 of the device410 includes angled side surfaces 427 that extend from a lower side toan upper side of the semiconductor layer 18 along a side portion of thesemiconductor layer 18 (e.g., the left-hand side portion as shown inFIG. 7B). The semiconductor layer 18 of the device 410 further includesan angled surface 423 at the upper side of the semiconductor layer 18along an opposite side portion (e.g., the right-hand side portion asshown in FIG. 7B) as the angled side surfaces 427.

The angled surface 423 of the semiconductor layer 18 may besubstantially the same or identical to the angled surfaces 23 of thedevice 10 of FIG. 1 and/or of the angled surfaces 323 of the device 310of FIGS. 6A and 6B shown and described previously herein.

The angled side surfaces 427 of the device 410 may be substantiallysymmetrical to one another and may be formed to have any angle suitableto facilitate total internal reflection of radiation at the interface ofthe angled side surfaces 427 and the cover layer 20, portions of thecover layer 20 in the cavity 414, or sidewall spacers 422 in the cavity414.

As shown in FIG. 7B, an optical a path length (or quantum effect length)of the incident radiation 30 within the semiconductor layer 18 includesa first segment 431, a second segment 432, a third segment 433, a fourthsegment 434, and a fifth segment 435. The incident radiation 30 may bereceived at a lower surface of the semiconductor layer 18 and travelsalong the first segment 431 of the quantum effect length until itencounters the angled surface 423 at the upper side of the semiconductorlayer 18, where the radiation 30 is totally internally reflected at theinterface between the angled surface 423 and the cover layer 20. Thetotally internally reflected radiation then travels along the secondsegment 432 of the quantum effect length until it encounters a firstangled side surface 427 (e.g., as shown at the front of the left-handside in FIG. 7B), where it may be totally internally reflected at theinterface of the first angled side surface 427 and the cover layer 20 orsidewall spacer 422. The radiation 30 travels then along the thirdsegment 433 of the quantum effect length until it encounters a secondangled side surface 427 (e.g., as shown at the back of the left-handside in FIG. 7B), where it may be totally internally reflected at theinterface of the second angled side surface 427 and the cover layer 20or sidewall spacer 422. The radiation 30 may then travel along thefourth segment 434 of the quantum effect length until it encounters athird angled side surface 427 (e.g., as shown at the back of theright-hand side in FIG. 7B), where it may be totally internallyreflected toward a front side of the semiconductor layer 18.

It will be readily appreciated that the device 410 shown in FIGS. 7A and7B may be formed by the method illustrated in FIGS. 3A through 3E withone or more modifications. For example, the cavity 414 may be formed bya substantially same process as described and illustrated with respectto FIG. 3B, and may have a rectangular shape, or may be formed to have ashape that corresponds with the side surfaces of the semiconductor layer18, for example, with angled side surfaces in the cavity 414 thatcorrespond with the angled side surfaces 427 of the semiconductor layer18. The sidewall spacers 422 may be formed by thermal oxidation, asdescribed with respect to FIG. 3C. The semiconductor layer 18 may beepitaxially grown from the exposed lower surface of the substrate 12, asdescribed with respect to FIG. 3D. In some embodiments, thesemiconductor layer 18 may be epitaxially grown in the cavity 414, andpost-growth processing (e.g., photolithography, etching, filmdeposition, etc.) may be performed to achieve a desired shape of thesemiconductor layer 18.

FIG. 8A is cross-sectional view illustrating a device 510 and FIG. 8B isa perspective view illustrating the semiconductor layer of the device510, in accordance with one or more embodiments of the presentdisclosure. The device 510 shown in FIGS. 8A and 8B is substantiallysimilar in many respects to the device 10 shown and described previouslyherein with respect to FIG. 1 . The description of the device 510 willfocus on the differences from the device 10 previously described herein.As shown in FIGS. 8A and 8B, the semiconductor layer 18 of the device510 includes a lower surface 515 on the substrate 12 at a floor of thecavity 514. Lower angled surfaces 525 extend outwardly and upwardly fromthe lower surface 515 of the semiconductor layer 18, and upper angledsurfaces 523 extend upwardly and inwardly from the lower angled surfaces525.

The lower and upper angled surfaces 525, 523 of the device 510 may besubstantially symmetrical to one another and may be formed to have anyangle suitable to facilitate total internal reflection of radiation atthe various interfaces between the lower and upper angled surfaces 525,523 and the cover layer 20, portions of the cover layer 20 in the cavity514, or sidewall spacers 522 in the cavity 514.

As shown in FIG. 8A, an optical a path length (or quantum effect length)of the incident radiation 30 within the semiconductor layer 18 includesa first segment 531, a second segment 532, a third segment 533, a fourthsegment 534, and a fifth segment 535. The incident radiation 30 may bereceived at the lower surface 515 of the semiconductor layer 18 andtravels along the first segment 531 of the quantum effect length untilit encounters a first upper angled surface 523 at the upper side of thesemiconductor layer 18 (e.g., as shown at the upper right-hand side inFIG. 8A), where the radiation 30 is totally internally reflected at theinterface between the first upper angled surface 523 and the cover layer20. The totally internally reflected radiation then travels along thesecond segment 532 of the quantum effect length until it encounters asecond upper angled surface 523 (e.g., as shown at the upper left-handside in FIG. 8A), where it may be totally internally reflected at theinterface of the second upper angled surface 523 and the cover layer 20.The radiation 30 then travels along the third segment 533 of the quantumeffect length until it encounters a first lower angled surface 525(e.g., as shown at the lower left-hand side in FIG. 8A), where it may betotally internally reflected at the interface of the first lower angledsurface 525 and the cover layer 20 or sidewall spacer 522. The radiation30 may then travel along the fourth segment 534 of the quantum effectlength until it encounters a second lower angled surface 525 (e.g., asshown at the lower right-hand side in FIG. 8A), where it may be totallyinternally reflected and travels along the fifth segment 535 toward thefirst angled surface 523 of the semiconductor layer 18, where it mayagain be totally internally reflected. The radiation 30 may continue tobe totally internally reflected at the various interfaces of thesemiconductor layer 18 and the cover layer 20 or sidewall spacers 522.

It will be readily appreciated that the device 510 shown in FIGS. 8A and8B may be formed by the method illustrated in FIGS. 3A through 3E withone or more modifications. For example, the cavity 514 may be formed bya substantially same process as described and illustrated with respectto FIG. 3B; however, the cavity 514 may be formed to have angledsurfaces that correspond to the lower angled surfaces 525 of thesemiconductor layer 18. The sidewall spacers 522 may be formed bythermal oxidation, as described with respect to FIG. 3C. Thesemiconductor layer 18 may be epitaxially grown from the exposed lowersurface 515 of the substrate 12, as described with respect to FIG. 3D.In some embodiments, the semiconductor layer 18 may be epitaxially grownin the cavity 514, and post-growth processing (e.g., photolithography,etching, film deposition, etc.) may be performed to achieve a desiredshape of the semiconductor layer 18.

FIG. 9A is cross-sectional view illustrating a device 610 and FIG. 9B isa perspective view illustrating the semiconductor layer of the device610, in accordance with one or more embodiments of the presentdisclosure. The device 610 shown in FIGS. 9A and 9B is substantiallysimilar in many respects to the device 10 shown and described previouslyherein with respect to FIG. 1 . The description of the device 610 willfocus on the differences from the device 10 previously described herein.As shown in FIGS. 9A and 9B, the semiconductor layer 18 of the device610 may have a substantially inverted U-shape with lower surfaces 615 onthe substrate 12 at the floor of the cavity 614. Portions of thesemiconductor layer 18 are separated or spaced apart from one another ata lower region of the semiconductor layer 18 by a segment of adielectric material 650, which in some embodiments may be formed of thesame material as the cover layer 20 or sidewall spacers 622.

The semiconductor layer 18 has outer side surfaces 619 that abut orcontact the sidewall spacers 622, and inner side surfaces 627 that abutor contact the segment of dielectric material 650. The semiconductorlayer 18 of the device 610 further includes angled surfaces 623 at theupper side of the semiconductor layer 18 that extend between the outerside surfaces 619 and the upper surface 621.

The angled surfaces 623 and upper surface 621 may be substantially thesame or identical to the angled surfaces 23 and upper surface 21,respectively, of the device 10 shown and described previously herein.

As shown in FIG. 9A, an optical a path length (or quantum effect length)of the incident radiation 30 within the semiconductor layer 18 mayinclude a variety of segments and the incident radiation 30 may betotally internally reflected at a variety of interfaces between thesemiconductor layer 18 and one or more of the cover layer 20, thesidewall spacers 622, or the segment of dielectric material 650.

It will be readily appreciated that the device 610 shown in FIGS. 9A and9B may be formed by the method illustrated in FIGS. 3A through 3E withone or more modifications. For example, the cavity 614 may be formed bya substantially same process as described and illustrated with respectto FIG. 3B. The sidewall spacers 622 may be formed by thermal oxidation,as described with respect to FIG. 3C, the segment of dielectric material650 may be formed by any suitable technique, including, for example, bythermal oxidation or the like. In some embodiments, the segment ofdielectric material 650 may be formed by forming a dielectric layer(e.g., by deposition, oxidation, or any suitable technique) in thecavity 614 (which may be performed in a same process as the formation ofthe sidewall spacers 622), and portions of the dielectric layer may beselectively removed (e.g., by etching) to form the segment of dielectricmaterial 650. The semiconductor layer 18 may be epitaxially grown fromthe exposed lower surfaces 615 of the substrate 12, as described withrespect to FIG. 3D.

FIG. 10A is cross-sectional view illustrating a device 710 and FIG. 10Bis a perspective view illustrating the semiconductor layer of the device710, in accordance with one or more embodiments of the presentdisclosure. The device 710 shown in FIGS. 10A and 10B is substantiallythe same as the device 610 shown and described with respect to FIGS. 9Aand 9B, except for the differences noted below. In particular, thedifference between the device 710 of FIGS. 10A and 10B and the device610 of FIGS. 9A and 9B is that the device 710 does not include theangled surfaces 623. Instead, the semiconductor layer 18 of the device710 has an upper surface 721 that extends between the outer sidesurfaces 719.

As shown in FIG. 10A, an optical a path length (or quantum effectlength) of the incident radiation 30 within the semiconductor layer 18may include a variety of segments and the incident radiation 30 may betotally internally reflected at a variety of interfaces between thesemiconductor layer 18 and one or more of the cover layer 20, thesidewall spacers 722, or the segment of dielectric material 750.

The device 710 may be formed in a substantially similar manner asdescribed with respect to forming the device 610; however, angledsurfaces are not formed at the upper portion of the device 710. Instead,the upper surface 721 of the device 710 may be formed, for example, byepitaxial growth of the semiconductor layer or post-growth processing(e.g., photolithography, etching, CMP, etc.) may be performed to achievea desired shape of the semiconductor layer 18. For example, in someembodiments, the device 710 may be formed by planarizing (e.g., by CMP)an upper surface of the semiconductor layer 18 of the device 610 toremove the angled surfaces.

The present disclosure provides, in various embodiments, photonicdevices, structures, and methods in which a semiconductor layer thatreceives incident irradiation and converts the received irradiation intoan electrical signal has a high quantum efficiency. The quantumefficiency may be achieved by increasing the quantum effect length ofthe received irradiation through the semiconductor material, which insome embodiments is facilitated by total internal reflection of theirradiation within the semiconductor material. By increasing the quantumeffect length of the received irradiation through total internalreflection, the height, as well as other dimensions of the semiconductorlayer, may be significantly reduced as compared to structures in whichradiation is not totally internally reflected.

According to one embodiment, a photonic device includes a substratehaving a first surface. A cavity extends into the substrate from thefirst surface to a second surface. A semiconductor layer is disposed onthe second surface in the cavity of the substrate, and a cover layer isdisposed on the semiconductor layer. The semiconductor layer isconfigured to receive incident radiation through the substrate and tototally internally reflect the radiation at an interface between thesemiconductor layer and the cover layer.

According to another embodiment, a method is provided that includesforming a cavity in a substrate. The cavity is formed to extend into thesubstrate from a first surface to a second surface. Sidewall spacers areformed on sidewalls of the substrate in the cavity. A semiconductorlayer is formed on the second surface in the cavity of the substrate,and the semiconductor layer abuts the sidewall spacers in the cavity.

According to yet another embodiment, an imaging device includes a firstsubstrate having a first surface. A plurality of cavities extend intothe first substrate from the first surface. An array of photodetectorsis formed in the plurality of cavities of the first surface. Each of thephotodetectors includes a semiconductor layer on the second surface inthe cavity of the substrate, and a cover layer on the semiconductorlayer. The semiconductor layer is configured to receive incidentradiation through the first substrate and to totally internally reflectthe radiation at an interface between the semiconductor layer and thecover layer. The imaging device further includes electrical circuitryelectrically coupled to the array of photodetectors and configured toreceive and process electrical signals generated by the array ofphotodetectors in response to receiving the incident radiation.

The foregoing outlines features of several embodiments so that thoseskilled in the art may better understand the aspects of the presentdisclosure. Those skilled in the art should appreciate that they mayreadily use the present disclosure as a basis for designing or modifyingother processes and structures for carrying out the same purposes and/orachieving the same advantages of the embodiments introduced herein.Those skilled in the art should also realize that such equivalentconstructions do not depart from the spirit and scope of the presentdisclosure, and that they may make various changes, substitutions, andalterations herein without departing from the spirit and scope of thepresent disclosure.

The various embodiments described above can be combined to providefurther embodiments. These and other changes can be made to theembodiments in light of the above-detailed description. In general, inthe following claims, the terms used should not be construed to limitthe claims to the specific embodiments disclosed in the specificationand the claims, but should be construed to include all possibleembodiments along with the full scope of equivalents to which suchclaims are entitled. Accordingly, the claims are not limited by thedisclosure.

The invention claimed is:
 1. A photonic device, comprising: a substratehaving a first surface and a cavity extending into the substrate fromthe first surface to a second surface; a semiconductor layer on thesecond surface in the cavity of the substrate; a cover layer on thesemiconductor layer; and sidewall spacers between side surfaces of thecavity and side surfaces of the semiconductor layer, wherein thesemiconductor layer is configured to receive incident radiation throughthe substrate and to totally internally reflect the radiation at aninterface between the semiconductor layer and the cover layer.
 2. Thephotonic device of claim 1, wherein the semiconductor layer having afirst refractive index, and the cover layer has a second refractiveindex that is less than the first refractive index.
 3. The photonicdevice of claim 2, wherein the first refractive index is within a rangefrom 2 to 6, and the second refractive index is within a range from 0 to2.
 4. The photonic device of claim 1, wherein the semiconductor layerincludes at least one of germanium (Ge), silicon germanium (SiGe), orany Group III-V semiconductor material.
 5. The photonic device of claim4, wherein the cover layer includes at least one of silicon oxide(SiO_(x)), silicon oxynitride (SiON), or silicon nitride (SiN).
 6. Thephotonic device of claim 1, wherein the sidewall spacers are formed of asame material as the cover layer.
 7. The photonic device of claim 1,further comprising a dielectric layer between the first surface of thesubstrate and the cover layer.
 8. The photonic device of claim 1,wherein the semiconductor layer has at least one angled surface havingan inclination angle between 30° and 60° with respect to the secondsurface of the substrate.
 9. The photonic device of claim 1, wherein thecavity has a depth between the second surface and the first surface ofthe substrate that is less than 700 μm, and the semiconductor layer hasa height from the second surface of the substrate that is less than 750μm.
 10. The photonic device of claim 1, further comprising a dielectricmaterial on the second surface in the cavity of the substrate, portionsof the semiconductor layer being spaced laterally apart from one anotherin the cavity by the dielectric material.
 11. An imaging device,comprising: a first substrate having a first surface and a plurality ofcavities extending into the first substrate from the first surface; anarray of photodetectors formed in the plurality of cavities of the firstsubstrate, each of the photodetectors including: a semiconductor layeron a second surface in the cavity of the first substrate; and a coverlayer on the semiconductor layer, the cover layer including wallstructures on outer sidewalls of the semiconductor layer, wherein a wallstructure separates an inner surface of the cavity from an outersidewall of a photodetector, wherein the semiconductor layer isconfigured to receive incident radiation through the first substrate andto totally internally reflect the radiation at an interface between thesemiconductor layer and the cover layer; and electrical circuitryelectrically coupled to the array of photodetectors and configured toreceive and process electrical signals generated by the array ofphotodetectors in response to receiving the incident radiation.
 12. Theimaging device of claim 11, further comprising: a second substrate, theelectrical circuitry being at least partially formed in the secondsubstrate; and an interconnect structure electrically and physicallycoupled between the first substrate and the second substrate, theelectrical circuitry being electrically coupled to the array ofphotodetectors through the interconnect structure.
 13. The imagingdevice of claim 11, further comprising: a plurality of optical lenses ona surface of the first substrate that is opposite the first surface,each of the optical lenses configured to focus the incident radiation toa respective one of the photodetectors.
 14. The imaging device of claim11, wherein the semiconductor layer has at least one angled surfacehaving an inclination angle between 30° and 60° with respect to one ofthe outer sidewalls of the semiconductor layer.
 15. A photonic device,comprising: a substrate having a frontside and a backside; a dielectriclayer extending over the frontside of the substrate, wherein a recessextends through the dielectric layer and continues into the frontside ofthe substrate to define inner substrate sidewalls that extend to arecessed frontside surface of the substrate; a semiconductor layerarranged on the recessed frontside surface of the substrate, thesemiconductor layer having outer sidewalls that are spaced apart fromthe inner substrate sidewalls by a distance; and a cover layer extendingover the dielectric layer and having sidewall spacers that separate theinner substrate sidewalls and the outer sidewalls of the semiconductorlayer to span the distance, the sidewall spacers and the cover layerbeing a continuous body and being made of the same material as oneanother; and wherein the semiconductor layer has a first refractiveindex, and the cover layer and the sidewall spacers have a secondrefractive index that is less than the first refractive index.
 16. Thephotonic device of claim 15, wherein the semiconductor layer isconfigured to receive incident radiation through the backside of thesubstrate and to totally internally reflect the radiation at aninterface between the semiconductor layer and the cover layer.
 17. Thephotonic device of claim 15, wherein the semiconductor layer includes atleast one of germanium (Ge), silicon germanium (SiGe), or any GroupIII-V semiconductor material.
 18. The photonic device of claim 15,wherein the cover layer and the sidewall spacers include at least one ofsilicon oxide (SiO_(x)), silicon oxynitride (SiON), or silicon nitride(SiN).
 19. The photonic device of claim 15, wherein the semiconductorlayer has at least one angled surface having an inclination anglebetween 30° and 60° with respect to one of the outer sidewalls of thesemiconductor layer.
 20. The photonic device of claim 15, wherein thesemiconductor layer has peripheral regions that directly contact therecessed frontside surface of the substrate and has central portion thatis raised to be spaced apart from the recessed frontside surface of thesubstrate, and wherein a segment of dielectric material having the samematerial as the cover layer separates the central portion of thesemiconductor layer from the recessed frontside surface of thesubstrate.